Enhancing Thermal Properties of Carbon Aluminum Composites

• US 20110027603A1
• Filed: 12/02/2009
• Published: 02/03/2011
• Est. Priority Date: 12/03/2008
• Status: Abandoned Application

• Current Assignee: Applied Nanotech, Inc. (Nano Magic, Inc.)
• Original Assignee: Applied Nanotech, Inc. (Nano Magic, Inc.)
• Inventors: Yang, Mohshi, Fink, Richard, Mao, Dongsheng, Pavlovsky, Igor, Jiang, Nan, Kim, Samuel, Yaniv, Zvi, Novak, James P.
• Application Number:
  US12/629,853
• Publication Number:
  US 20110027603A1
• Time in Patent Office: Days
• US Class Current: 428/550
• CPC Class Codes: B32B 5/18 characterised by features of a layer of foamed material
• CPC Class Codes: C04B 2111/00844 for electronic applications
• CPC Class Codes: C04B 2235/3817 Carbides
• CPC Class Codes: C04B 2235/3826 Silicon carbides
• CPC Class Codes: C04B 2235/402 Aluminium
• CPC Class Codes: C04B 2235/428 Silicon
• CPC Class Codes: C04B 2235/6021 Extrusion moulding
• CPC Class Codes: C04B 2235/616 Liquid infiltration of green bodies or pre-forms
• CPC Class Codes: C04B 2235/80 Phases present in the sintered or melt-cast ceramic products other than the main phase
• CPC Class Codes: C04B 2235/9607 Thermal properties, e.g. thermal expansion coefficient
• CPC Class Codes: C04B 35/522 Graphite C04B35/536 takes precedence
• CPC Class Codes: C04B 35/528 obtained from carbonaceous particles with or without other non-organic components
• CPC Class Codes: C04B 35/645 Pressure sintering
• CPC Class Codes: C04B 41/009 characterised by the material treated
• CPC Class Codes: C04B 41/4521 application under increased pressure
• CPC Class Codes: C04B 41/4523 applied from the molten state vitreous materials C04B41/5022; Thermal spraying, e.g. plasma spraying
• CPC Class Codes: C04B 41/5096 Silicon C04B35/573 takes precedence
• CPC Class Codes: C04B 41/5155 Aluminium
• CPC Class Codes: C04B 41/88 Metals
• CPC Class Codes: C09K 5/14 Solid materials, e.g. powdery or granular
• CPC Class Codes: C22C 1/08 : Alloys with open or closed pores
• CPC Class Codes: C22C 1/081 : Casting porous metals into porous preform skeleton without foaming
• CPC Class Codes: C22C 1/1036 : starting from a melt
• CPC Class Codes: C22C 32/0084 : carbon or graphite as the main non-metallic constituent
• CPC Class Codes: H01L 23/373 : Cooling facilitated by selection of materials for the device or materials for thermal expansion adaptation, e.g. carbon
• CPC Class Codes: H01L 23/3736 : Metallic materials H01L23/3732, H01L23/3733, H01L23/3735, H01L23/3737, H01L23/3738 take precedence
• CPC Class Codes: H01L 2924/00 : Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
• CPC Class Codes: H01L 2924/0002 : Not covered by any one of groups H01L24/00, H01L24/00 and H01L2224/00
• CPC Class Codes: H01L 2924/3011 : Impedance
• CPC Class Codes: Y10T 428/12042 : Porous component
• CPC Class Codes: Y10T 428/249994 : Composite having a component wherein a constituent is liquid or is contained within preformed walls [e.g., impregnant-filled, previously void containing component, etc.]

Abstract

An article of manufacture comprises a carbon-containing matrix. The carbon-containing matrix may comprise at least one type of carbon material selected from the group comprising graphite crystalline carbon materials, carbon powder, and artificial graphite powder. In addition, the carbon-containing matrix comprises a plurality of pores. The article of manufacture also comprises a metal component comprising Al, alloys of Al, or combinations thereof. The metal component is disposed in at least a portion of the plurality of pores. Further, the article of manufacture comprises an additive comprising at least Si. At least a portion of the additive is disposed in an interface between the metal component within the pores and the carbon-containing matrix. The additive enhances phonon coupling and propagation at the interface.

Claims

1. An article of manufacture comprising:

a carbon-containing matrix comprising at least one type of carbon material selected from the group comprising graphite crystalline carbon materials, carbon powder, and artificial graphite powder, or combinations thereof, the carbon-containing matrix comprising a plurality of pores;

a metal component comprising Al, alloys of Al, or combinations thereof, the metal component disposed in at least a portion of the plurality of pores; and

an additive comprising at least Si, at least a portion of the additive disposed in an interface between the metal component within the pores and the carbon-containing matrix, the additive enhancing phonon coupling and propagation at the interface.

2. The article of manufacture of claim 1, wherein the metal component is disposed in at least 90% by volume of the plurality of pores.

3. The article of manufacture of claim 1, wherein the additive is disposed in the metal component and in the interface.

4. The article of manufacture of claim 3, wherein the additive comprises less than 11% by mass of the metal component.

5. The article of manufacture of claim 3, wherein the additive comprises more than 5% by mass of the metal component.

6. The article of manufacture of claim 1, wherein the additive comprises Si crystals.

7. The article of manufacture of claim 1, wherein the interface comprises Si crystals, SiC, Al_aSi_bC_c, or combinations thereof.

8. The article of manufacture of claim 1, further comprising not more than 1% of Al₄C₃.

9. The article of manufacture of claim 1, wherein a thickness of the interface is less than 100 nm.

10. The article of manufacture of claim 1 having a thermal conductivity in the range of 300 W/mK to 600 W/mK.

11. The article of manufacture of claim 1 having a thermal diffusivity in the range of 0.8 cm²/s to 3.2 cm²/s.

12. A method of making the article of manufacture of claim 1 comprising:

providing the carbon-containing matrix, the metal component, and the additive to a mold;

pressurizing the mold to a pressure within the range of 80 MPa to 100 MPa, to a temperature in the range of 700°

C. to 800°

C. for a duration in the range of 10 minutes to 20 minutes.

13. The method of claim 12, further comprising pre-heating the carbon-containing matrix to a temperature in the range of 700°

C. to 750°

C. and pre-heating the mold and a die to a temperature of about 250°

C. before pressurizing the mold.

14. The method of claim 12, further comprising melting the metal component at a temperature in the range of 700°

C. to 750°

C. before pressurizing the mold.

15. The method of claim 14, further comprising pre-mixing the additive with the metal component before melting the metal component.

16. The method of claim 14, further comprising adding the additive to the metal component after melting the metal component.

17. The method of claim 12, further comprising heating a carbon block to a temperature in the range 3200°

C. to 3600°

C. for a duration in the range of 2 days to 3 days to form the carbon-containing matrix.

18. The method of claim 17, further comprising extruding petroleum cork, needle cork, tar, or mixtures thereof, at a temperature in the range of 500°

C. to 800°

C. to form the carbon block.

19. The method of claim 12, further comprising machining the article of manufacture of claim 1 into a heat transfer device.

20. An article of manufacture made by a method comprising:

providing a carbon-containing matrix, an amount of Si, and solid or molten Al or alloy of Al to a mold, the carbon-containing matrix comprising at least one type of carbon material selected from the group comprising graphite crystalline carbon materials, carbon powder, artificial graphite powder, or combinations thereof; and

pressurizing the mold to a pressure within the range of 80 MPa to 100 MPa, to a temperature in the range of 700°

C. to 800°

C. for a duration in the range of 10 minutes to 20 minutes.

21. An article of manufacture comprising:

a carbon-containing matrix comprising at least one type of carbon material selected from the group comprising graphite crystalline carbon materials, carbon powder, and artificial graphite powder, or combinations thereof, the carbon-containing matrix comprising a plurality of pores;

wherein the carbon-containing matrix is made by a high pressure mold press;

a metal component comprising Al, alloys of Al, or combinations thereof, the metal component disposed in at least a portion of the plurality of pores; and

an additive comprising at least Si, at least a portion of the additive disposed in an interface between the metal component within the pores and the carbon-containing matrix, the additive enhancing phonon coupling and propagation at the interface.

22. The article of manufacture of claim 21, wherein a maximum thermal conductivity is perpendicular to a direction of pressure exerted by the high pressure mold press on the carbon-containing matrix during formation of the carbon-containing matrix.

23. An article of manufacture comprising:

a carbon-containing matrix comprising at least one type of carbon material selected from the group comprising graphite crystalline carbon materials, carbon powder, and artificial graphite powder, or combinations thereof, the carbon-containing matrix comprising a plurality of pores;

wherein the carbon-containing matrix is made by extrusion;

a metal component comprising Al, alloys of Al, or combinations thereof, the metal component disposed in at least a portion of the plurality of pores; and

an additive comprising at least Si, at least a portion of the additive disposed in an interface between the metal component within the pores and the carbon-containing matrix, the additive enhancing phonon coupling and propagation at the interface.

24. The article of manufacture of claim 23, wherein a maximum thermal conductivity is parallel to a direction of extrusion during formation of the carbon-containing matrix.